Toshiba RAS-107SKV-E2, RAS-107SAV-E2 SERVICE MANUAL

FILE NO. SVM-09051

SERVICE MANUAL

	SPLIT TYPE
Indoor Unit	Outdoor Unit
<High Wall, Heat Pump Type>	<Heat Pump Type>
RAS-107SKV-E2	RAS-107SAV-E2

R410A

March, 2009

FILE NO. SVM-09051

CONTENTS

1.	SAFETY PRECAUTIONS ..........................................................................	2
2.	SPECIFICATIONS .....................................................................................	4
3.	REFRIGERANT R410A .............................................................................	6
4.	CONSTRUCTION VIEWS ........................................................................	14
5.	WIRING DIAGRAM ..................................................................................	16
6.	SPECIFICATIONS OF ELECTRICAL PARTS .........................................	18
7.	REFRIGERANT CYCLE DIAGRAM ........................................................	20
8.	CONTROL BLOCK DIAGRAM ................................................................	22
9.	OPERATION DESCRIPTION ...................................................................	24
10.	INSTALLATION PROCEDURE ................................................................	44
11.	HOW TO DIAGNOSE THE TROUBLE ......................................................	57
12.	HOW TO REPLACE THE MAIN PARTS ...................................................	72
13.	EXPLODED VIEWS AND PARTS LIST ...................................................	80

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FILE NO. SVM-09051

1. SAFETY PRECAUTIONS

For general public use

Power supply cord of outdoor unit shall be more than 1.5 mm2 (H07RN-F or 60245IEC66) polychloroprene sheathed flexible cord.

•Read this “SAFETY PRECAUTIONS” carefully before servicing.

•The precautions described below include the important items regarding safety. Observe them without fail.

•After the servicing work, perform a trial operation to check for any problem.

•Turn off the main power supply switch (or breaker) before the unit maintenance.

CAUTION

New Refrigerant Air Conditioner Installation

•THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.

R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant R410A air conditioner circuit.

To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those used for the conventional refrigerant units.

Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does not enter. Moreover, do not use the existing piping because there are some problems with pressure fittings and possible impurities in existing piping.

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY

This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact separation of at least 3 mm.

DANGER

•ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/MAINTAIN THE AIR CONDITIONER.

INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE.

•TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

DANGER: HIGH VOLTAGE

The high voltage circuit is incorporated.

Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

•CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED.

•CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

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FILE NO. SVM-09051

•DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

•TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.

•WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.

•IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY RESULT.

WARNING

•Never modify this unit by removing any of the safety guards or bypass any of the safety interlock switches.

•Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.

•After the installation work, confirm that refrigerant gas does not leak.

If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may generate.

•The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive circuit.

An insufficient circuit capacity or inappropriate installation may cause fire.

•When wiring, use the specified cables and connect the terminals securely to prevent external forces applied to the cable from affecting the terminals.

•Be sure to provide grounding.

Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

•Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

CAUTION

•Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water.

•Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where noise or discharged air might disturb neighbors.

•To avoid personal injury, be careful when handling parts with sharp edges.

•Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

For Reference:

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner.

For details, contact the dealer.

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				2. SPECIFICATIONS			FILE NO. SVM-09051
2-1. Specifications
	Unit model	Indoor					RAS-107SKV-E2
		Outdoor					RAS-107SAV-E2
	Cooling capacity				(kW)		2.5
	Cooling capacity range				(kW)		1.1 - 3.0
	Heating capacity				(kW)		3.2
	Heating capacity range				(kW)		0.9 - 4.1
	Power supply						1Ph/50Hz/220-240V
	Electric	Indoor	Operation mode			Cooling		Heating
	characteristic		Running current		(A)	0.16 - 0.14		0.16 - 0.14
			Power consumption		(W)	30		30
			Power factor		(%)	87		87
		Outdoor	Operation mode			Cooling		Heating
			Running current		(A)	3.49 - 3.21		4.03- 3.70
			Power consumption		(W)	730		840
			Power factor		(%)	95		96
			Starting current		(A)		4.15 - 3.80
	COP (Cooling / Heating)						3.29/3.68
	Operating	Indoor	High	(Cooling / Heating)	(dB-A)		38/40
	noise		Medium	(Cooling / Heating)	(dB-A)		33/35
			Low	(Cooling / Heating)	(dB-A)		29/30
		Outdoor		(Cooling / Heating)	(dB-A)		48/50
	Indoor unit	Unit model					RAS-107SKV-E2
		Dimension	Height		(mm)		250
			Width		(mm)		740
			Depth		(mm)		195
		Net weight			(kg)		8
		Fan motor output			(W)		20
		Air flow rate		(Cooling / Heating)	(m3 / min)		8.7/9.6
	Outdoor unit	Unit model					RAS-107SAV-E2
		Dimension	Height		(mm)		530
			Width		(mm)		660
			Depth		(mm)		240
		Net weight			(kg)		29
		Compressor	Motor output		(W)		750
			Type			Single rotary type with DC-inverter variable speed control
			Model				DA89X1C-23EZ
		Fan motor output			(W)		20
		Air flow rate		(Cooling / Heating)	(m3 / min)		27/27
	Piping	Type					Flare connection
	connection	Indoor unit	Liquid side		(mm)		6.35
			Gas side		(mm)		9.52
		Outdoor unit	Liquid side		(mm)		6.35
			Gas side		(mm)		9.52
		Maximum length			(m)		10
		Maximun charge-less length			(m)		10
		Maximum height difference			(m)		8
	Refrigerant	Name of refrigerant					R410A
		Weight			(kg)		0.63
	Wiring		Power supply			3 Wires: Includes earth (Outdoor)
	connection		Interconnection				4 Wires: Includes earth
	Usable temperature range		Indoor	(Cooling / Heating)	(oC)		21 - 32/Up to 27
			Outdoor	(Cooling / Heating)	(oC)		15 - 43/-10 - 24
	Accessory	Indoor unit	Installation plate				1
			Wireless remote controller				1
			batteries				2
			Remote controller holder				1
			Active Corbon Catechin filter				2
			Mounting screw				6 ( 4 x 25L)
			Pan head wood screw				2 ( 3.1 x 16L)
			Plasma air purifier				-
			Installation manual				1
			Owner's manual				1
		Outdoor unit	Drain nipple				1
			Water proof rubber cap				-

* The specification may be subject to change without notice for purpose of improvement.

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FILE NO. SVM-09051

2-2. Operation Characteristic Curve

<Cooling>

	6
	5
	4
(A)
Current	3
	2
									Conditions
	1								Indoor : DB 27°C/WB 19°C
									Outdoor : DB 35°C/WB 24°C
									Air Flow : High
									Pip Length : 5m
									Voltage : 230V
	0
	0	10	20	30	40	50	60	70	80	90	100	110	120
				Compressor Speed (rps)

<Heating>

	6
	5
	4
(A)
Current	3
	2
								Conditions
	1							Indoor : DB 20°C/WB 15°C
								Outdoor : DB 7°C/WB 6°C
								Air Flow : High
								Pip Length : 5m
								Voltage : 230V
	0
	0	10	20	30	40	50	60	70	80	90	100	110	120
				Compressor Speed (rps)

2-3. Capacity Variation Ratio According to Temperature
<Cooling>													<Heating>
	105													120
	100
	95													100
	90												(%)
(%)	85												ratio	80
CapacityCoolingratio	80												CapacityHeating
														60
	75
	70													40
	65
					Capacity ratio 100% is 2.5kw										Capacity ratio 100% is 3.2kw
	60							Conditions						20		Conditions
								Indoor : DB 27°C/WB 19°C								Indoor : DB 20°C/WB 15°C
	55							Indoor Air Flow : High								Indoor Air Flow : High
								Pip Length : 5m								Pip Length : 5m
								Voltage : 230V								Voltage : 230V
	50													0
	32	33	34	35	36	37	38	39	40	41	42	43		-10	-5	0	5	10
				Outside Temperature ( oC)												Outside Temperature ( ºC)

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FILE NO. SVM-09051

3. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

1.Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

2.Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22.

3.If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

4.When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

5.After completion of installation work, check to make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

6.When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

7.Be sure to carry out installation or removal according to the installation manual.

Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

8.Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair’s may result in water leakage, electric shock and fire, etc.

3-2. Refrigerant Piping Installation

3-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

1.Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 3-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market.

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FILE NO. SVM-09051

Table 3-2-1 Thicknesses of annealed copper pipes

			Thickness (mm)
Nominal diameter	Outer diameter (mm)	R410A	R22
1/4	6.35	0.80	0.80
3/8	9.52	0.80	0.80
1/2	12.70	0.80	0.80
5/8	15.88	1.00	1.00

2.Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a)Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below.

b)Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in Table 3-2-2.

Table 3-2-2 Minimum thicknesses of socket joints

	Nominal diameter	Reference outer diameter of	Minimum joint thickness
		copper pipe jointed (mm)	(mm)
	1/4	6.35	0.50
	3/8	9.52	0.60
	1/2	12.70	0.70
	5/8	15.88	0.80

3-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

1.Flare processing procedures and precautions

a)Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b)Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c)Insertion of Flare Nut

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FILE NO. SVM-09051

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

ØD

A

Fig. 3-2-1 Flare processing dimensions

Table 3-2-3 Dimensions related to flare processing for R410A

		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R410A	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	Clutch type	Wing nut type
	1/4	6.35	0.8		0 to 0.5	1.0 to 1.5	1.5 to 2.0
	3/8	9.52	0.8		0 to 0.5	1.0 to 1.5	1.5 to 2.0
	1/2	12.70	0.8		0 to 0.5	1.0 to 1.5	2.0 to 2.5
	5/8	15.88	1.0		0 to 0.5	1.0 to 1.5	2.0 to 2.5
		Table 3-2-4 Dimensions related to flare processing for R22
		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R22	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	Clutch type	Wing nut type
	1/4	6.35	0.8		0 to 0.5	0.5 to 1.0	1.0 to 1.5
	3/8	9.52	0.8		0 to 0.5	0.5 to 1.0	1.0 to 1.5
	1/2	12.70	0.8		0 to 0.5	0.5 to 1.0	1.5 to 2.0
	5/8	15.88	1.0		0 to 0.5	0.5 to 1.0	1.5 to 2.0

Table 3-2-5 Flare and flare nut dimensions for R410A

Nominal	Outer diameter	Thickness		Dimension (mm)					Flare nut width
diameter	(mm)	(mm)	A		B	C		D	(mm)
1/4	6.35	0.8	9.1		9.2	6.5		13	17
3/8	9.52	0.8	13.2		13.5	9.7		20	22
1/2	12.70	0.8	16.6		16.0	12.9		23	26
5/8	15.88	1.0	19.7		19.0	16.0		25	29

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																									FILE NO. SVM-09051
		Table 3-2-6 Flare and flare nut dimensions for R22
Nominal	Outer diameter								Thickness									Dimension (mm)												Flare nut width
diameter		(mm)									(mm)						A		B		C				D					(mm)
1/4	6.35								0.8							9.0			9.2	6.5					13					17
3/8	9.52								0.8							13.0			13.5	9.7					20					22
1/2	12.70								0.8							16.2			16.0	12.9					20					24
5/8	15.88								1.0							19.7			19.0	16.0					23					27
3/4	19.05								1.0							23.3			24.0	19.2					34					36
		to	46˚
		45˚
							B			A													C			D

				43˚	to
					45˚

Fig. 3-2-2 Relations between flare nut and flare seal surface

2.Flare Connecting Procedures and Precautions

a)Make sure that the flare and union portions do not have any scar or dust, etc.

b)Correctly align the processed flare surface with the union axis.

c)Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 3-2-7 shows reference values.

NOTE :

When applying oil to the flare surface, be sure to use oil designated by the manufacturer.

If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Table 3-2-7 Tightening torque of flare for R410A [Reference values]

	Nominal	Outer diameter	Tightening torque	Tightening torque of torque
				wrenches available on the market
	diameter	(mm)	N•m (kgf•cm)
				N•m (kgf•cm)
	1/4	6.35	14 to 18 (140 to 180)	16 (160), 18 (180)
	3/8	9.52	33 to 42 (330 to 420)	42 (420)
	1/2	12.70	50 to 62 (500 to 620)	55 (550)
	5/8	15.88	63 to 77 (630 to 770)	65 (650)

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FILE NO. SVM-09051

3-3. Tools

3-3-1. Required Tools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

1.Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))

2.Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)

3.Tools commonly used for R410A and for conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

				R410A		Conventional air-water
				air-water heat pump installation		heat pump installation
	No.	Used tool	Usage
				Existence of	Whether conven-	Whether new equipment
				new equipment	tional equipment	can be used with
				for R410A	can be used	conventional refrigerant
	1	Flare tool	Pipe flaring	Yes	*(Note 1)	¡
		Copper pipe gauge for	Flaring by		*(Note 1)	*(Note 1)
	2	adjusting projection		Yes
			conventional flare tool
		margin
	3	Torque wrench	Connection of flare nut	Yes	×	×
		(For Ø12.7)
	4	Gauge manifold	Evacuating, refrigerant	Yes	×	×
	5	Charge hose	charge, run check, etc.
	6	Vacuum pump adapter	Vacuum evacuating	Yes	×	¡
	7	Electronic balance for	Refrigerant charge	Yes	×	¡
		refrigerant charging
	8	Refrigerant cylinder	Refrigerant charge	Yes	×	×
	9	Leakage detector	Gas leakage check	Yes	×	¡
	10	Charging cylinder	Refrigerant charge	(Note 2)	×	×

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

1.Vacuum pump

Use vacuum pump by attaching vacuum pump adapter.

2.Torque wrench (For Ø6.35, Ø9.52)

3.Pipe cutter

4.	Reamer	9.	Hole core drill (Ø65)
5.	Pipe bender	10.	Hexagon wrench
6.	Level vial		(Opposite side 4mm)
7.	Screwdriver (+, –)	11.	Tape measure
8.	Spanner or Monkey wrench	12.	Metal saw

Also prepare the following equipments for other installation method and run check.

1.	Clamp meter	3.	Insulation resistance tester
2.	Thermometer	4.	Electroscope

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FILE NO. SVM-09051

3-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

Recover the refrigerant, and check no refrigerant remains in the equipment.

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant.

(For refrigerant charging, see the figure below.)

1.Never charge refrigerant exceeding the specified amount.

2.If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3.Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

	(Indoor unit)	(Outdoor unit)
		Opened
	Refrigerant cylinder
	(with siphon)
	Check valve	Opened
	Opened
	Open/close	Closed
	valve for charging
		Service port
	Electronic balance for refrigerant charging

Fig. 3-4-1 Configuration of refrigerant charging

– 11 –

FILE NO. SVM-09051

1.Be sure to make setting so that liquid can be charged.

2.When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ]	[ Cylinder without siphon ]
Gauge manifold	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

cylinder Refrigerant

Electronic

balance

Siphon

Fig. 3-4-2

3-5. Brazing of Pipes

3-5-1. Materials for Brazing

1.Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2.Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3.Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1.Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2.When performing brazing again at time of servicing, use the same type of brazing filler.

3-5-2. Flux

1.Reason why flux is necessary

•By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

•In the brazing process, it prevents the metal surface from being oxidized.

•By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

– 12 –

2.Characteristics required for flux

•Activated temperature of flux coincides with the brazing temperature.

•Due to a wide effective temperature range, flux is hard to carbonize.

•It is easy to remove slag after brazing.

•The corrosive action to the treated metal and brazing filler is minimum.

•It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3.Types of flux

•Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 800°C.

•Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4.Piping materials for brazing and used brazing filler/flux

Piping material	Used brazing filler	Used flux
Copper - Copper	Phosphor copper	Do not use
Copper - Iron	Silver	Paste flux
Iron - Iron	Silver	Vapor flux

1.Do not enter flux into the refrigeration cycle.

2.When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

3.When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4.Remove the flux after brazing.

FILE NO. SVM-09051

3-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

1.Brazing method to prevent oxidation

1)Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2)Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3)Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4)When the Nitrogen gas is flowing, be sure to keep the piping end open.

5)Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve.

6)After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7)Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

Fig. 3-5-1 Prevention of oxidation during brazing

– 13 –

FILE NO. SVM-09051

4. CONSTRUCTION VIEWS

4-1. Indoor Unit

Front panel

60

8

Knock out system

Air inlet	Air filter	Heat exchanger
		740
250

Air outlet

195
	52
58	8

Knock out system

50				50
55	60		60	55
105		500	135
Drain hose (0.5m)		290	Connecting pipe (0.37m)
			(Flare 6.35)
	Hanger		Connecting pipe (0.37m)
			(Flare 9.52)

45

250

605

235 235

215 215

Hanger

		Hanger		Hanger
90	135	145	145	135

For stud bold ( 8~ 10)

For stud bold ( 6)

26
45
165	135

40	54	16
38

90	Wireless remote control

Installation plate outline Center line

– 14 –

FILE NO. SVM-09051

4-2. Outdoor Unit

C

L

C

L

280

400

− 15 −

FILE NO. SVM-09051

5. WIRING DIAGRAM

5-1. Indoor Unit

– 16 –

FILE NO. SVM-09051

2.-5 UnitOutdoor

– 17 –

			FILE NO. SVM-09051
	6. SPECIFICATION OF ELECTRICAL PARTS
6-1. Indoor Unit
No.	Parts name	Type	Specifications
1	Fan motor (for indoor)	AFN-220-20-4D	AC Motor with 145°C thermo fuse
2	Thermo. sensor (TA-sensor)		10 kΩ at 25°C
3	Switching transformer (T01)	ST-02
4	Microcontroller unit (IC81)	μPD780076GK-703-9ET-A
5	Heat exchanger sensor		10 kΩ at 25°C
	(TC-sensor)
6	Line filter (L01)	SS11V-R06270	27 mH, AC 0.6A
7	Bridge diode (DB01)	DB105G	1A, 600V
8	Capacitor (C27)	EKMH401VSN470MP20S	47μF, 400V
9	Fuse (F01)	FJL250V3.15A	3.15A, 250 V
10	Regulator IC (IC02)	S7805PIC	5VDC, 0.5A
11	Varistor (R01)	SR561K14DL	560V
12	Louver motor	MP24ZCT	DC 12V

– 18 –

					FILE NO. SVM-09051
6-2. Outdoor Unit
No.	Parts name			Model name	Rating
1	SC coil		L01	GET-04051	0.6mH, 15A
	(Noise filter)		L03	GET-04052	10A, 2mH
2	DC-DC transformer			SWT-72	Primary side DC280V, Secondary
					side 7.0 V x 1, 12 V x 1, 17V x 2
3	Reactor			CH-69-Z-T	L=19mH, 10A
4	Outside fan motor			WLF-240-20A-1	20W
5	Fan control relay			G5NB-1A-CA	Coil DC12V Contact AC250V-1.5A
6	Outside air temp.			(Inverter attached)	10kΩ (25°C)
	sensor (TO sensor)
7	Dischenge temp.			(Inverter attached)	62kΩ (20°C)
	sensor (TD sensor)
8	Terminal block (5P)			JX0-5B	20A, AC250V
9	Fuse			For protection of switching power source	3.15A, AC250V
				For protection of inverter input overcurrent	25A, AC250V
10	Electrolytic capacitor			LLQ2G501KHUATF	500μF, DC 400 V x 3 pieces
11	IGBT			GT15J321	15A, 600V
12	Compressor			DA89X1C-23EZ	3-phases 4-poles 750W
13	Rectifier			D15XB60-4001	15A, 600V
14	Running capacitor			DS451155NPQB	AC 450V~, 1.5μF
	(for fan motor)
15	4-WAY valve coil			STF-01AJ646A1	AC 220-240V

– 19 –

FILE NO. SVM-09051

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

P Pressure measurement

Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 9.52mm Thickness : 0.8mm

	INDOOR UNIT	T1	Temp. measurement
	Indoor heat
	exchanger
		TC	heightAllowable 10m:difference	lengthpipeAllowable
	Cross flow fan	TA
	Deoxidized copper pipe
	Outer dia. : 6.35mm
	Thickness : 0.8mm
	Sectional shape
	of heat insulator

Max. : 10m

Min. : 2m

Chargeless : 10m

Muffler

4-way valve (STF-0108Z)

	Muffler
	TD
	Compressor
	DA89X1C-23EZ
	TO
	Outdoor heat
	exchanger	Ø1.0 x 600
Temp. measurement T2		Ø1.0 x 600
	T E

Propeller fan		Refrigerant amount : 0.63kg
OUTDOOR UNIT	NOTE :		Gas leak check position
			Refrigerant flow (Cooling)
			Refrigerant flow (Heating)

NOTE :

•The maximum pipe length of this air conditioner is 10 m. The addition charging of refrigevant is unnecessary because this air condition is design with charge-less specitication.

–20 –

FILE NO. SVM-09051

7-2. Operation Data

<Cooling>

Tempeature		Standard	Heat exchanger			Indoor	Outdoor	Compressor
condition(°C)		pressure	pipe temp.			fan mode	fan mode	revolution
Indoor	Outdoor	P (MPa)	T1 (°C)	T2 (°C)				(rps)
27/19	35/-	0.9 to 1.1	9 to 11	47 to	49	High	High	54
<Heating>
Tempeature		Standard	Heat exchanger			Indoor	Outdoor	Compressor
condition(°C)		pressure	pipe temp.			fan mode	fan mode	revolution
Indoor	Outdoor	P (MPa)	T1 (°C)	T2 (°C)				(rps)
20/-	7/6	2.4 to 2.6	43 to 45	0 to	3	High	High	68

NOTES :

1.Measure surface temperature of heat exchanger pipe around center of heat exchaner path U bent. (Thermistor themometer)

2.Connecting piping condition 5 m

– 21 –

FILE NO. SVM-09051

8. CONTROL BLOCK DIAGRAM

8-1. Indoor Unit

Indoor Unit Control Panel

M.C.U

Functions

Heat Exchanger Sensor

Operation

•

Louver Control

Display

•

Timer

Temperature Sensor

3-minute Delay at Restart for Compressor

•

Motor Revolution Control

Display

Infrared Rays Signal Receiver

•

Infrared

Initiallizing Circuit

Processing

(Temperature Processing)

Rays

Clock Frequency

•

Timer

Indoor

Fan Motor

36.7KHz

Oscillator Circuit

•

Serial Signal Communication

Power Supply

Remote

Circuit

Louver ON/OFF Signal

Control

Noise Filter

Louver Driver

Louver Motor

Serial Signal Transmitter/Receiver

From Outdoor Unit

Serial Signal Communication

REMOTE CONTROL

Infrared Rays

Remote Control

Operation ()

Operation Mode Selection

AUTO, COOL, DRY, HEAT

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

– 22 –

FILE NO. SVM-09051

8-2. Outdoor Unit (Inverter Assembly)

Compressor

MICRO-COMPUTERBLOCKDIAGRAM

P.C.B(MCC5009)

For INDOOR UNIT

Inverter	(DC AC)	Gatedrive circuit	Rotorposition detectcircuit
Over	current	sensor

Input Converter	current (AC DC) sensor	Highpowerfactor correctioncircuit	M.C.U	1.PWMsynthesisfunction 2.Inputcurrentreleasecontrol 3.IGBTover-currentdetectcontrol 4.Outdoorfancontrol 5.Highpowerfactorcorrectioncontrol 6.SignalcommunicationtoindoorunitM.C.U
Noise	filter

1

230V50Hz

signal

Discharge temp. sensor

Outdoor air temp. sensor

Relay

Fan motor

Relay

4way Valve

Heat Exchanger temp. sensor

– 23 –

							FILE NO. SVM-09051
		9. OPERATION DESCRIPTION
	9-1. Outline of Air Conditioner Control				•	Detection of inverter input current and current
	This air conditioner is a capacity-variable type air					release operation
					•	Over-current detection and prevention operation
	conditioner, which uses AC or DC motor for the indoor
						to IGBT module (Compressor stop function)
	for motor and the outdoor fan motor. And the capacity-
					•	Compressor and outdoor fan stop function when
	proportional control compressor which can change the
	motor speed in the range from 11 to 96 rps is					serial signal is off (when the serial signal does not
	mounted. The DC motor drive circuit is mounted to the					reach the board assembly of outdoor control by
	indoor unit. The compressor and the inverter to control					trouble of the signal system)
	fan motor are mounted to the outdoor unit.				•	Transferring of operation information (Serial
	The entire air conditioner is mainly controlled by the					signal) from outdoor unit controller to indoor unit
	indoor unit controller.					controller
	The indoor unit controller drives the indoor fan motor				•	Detection of outdoor temperature and operation
	based upon command sent from the remote controller,					revolution control
	and transfers the operation command to the outdoor				•	Defrost control in heating operation (Temp.
	unit controller.					measurement by outdoor heat exchanger and
	The outdoor unit controller receives operation com-					control for 4-way valve and outdoor fan)
	mand from the indoor unit side, and controls the				3. Contents of operation command signal
	outdoor fan and the pulse Modulating valve. (P.M.V)
					(Serial signal) from indoor unit controller to
	Besides, detecting revolution position of the compres-
					outdoor unit controller
	sor motor, the outdoor unit controller controls speed of
	the compressor motor by controlling output voltage of				The following three types of signals are sent from
	the inverter and switching timing of the supply power				the indoor unit controller.
	(current transfer timing) so that motors drive according				•	Operation mode set on the remote controller
	to the operation command.
					•	Compressor revolution command signal defined
	And then, the outdoor unit controller transfers reversely
						by indoor temperature and set temperature
	the operating status information of the outdoor unit to
						(Correction along with variation of room tempera-
	control the indoor unit controller.
						ture and correction of indoor heat exchanger
	As the compressor adopts four-pole brushless					temperature are added.)
	DC motor, the frequency of the supply power				•	Temperature of indoor heat exchanger
	from inverter to compressor is two-times cycles				•	For these signals ([Operation mode] and [Com-
	of the actual number of revolution.					pressor revolution] indoor heat exchanger tem-
	1. Role of indoor unit controller					perature), the outdoor unit controller monitors the
						input current to the inverter, and performs the
	The indoor unit controller judges the operation					followed operation within the range that current
						does not exceed the allowable value.
	commands from the remote controller and assumes
	the following functions.				4. Contents of operation command signal
	•	Judgment of suction air temperature of the indoor
					(Serial signal) from outdoor unit controller
		heat exchanger by using the indoor temp. sensor.
					to indoor unit controller
		(TA sensor)
					The following signals are sent from the outdoor unit
	•	Judgment of the indoor heat exchanger tempera-
					controller.
		ture by using heat exchanger sensor (TC sensor)
					•	The current operation mode
		(Prevent-freezing control, etc.)
	•	Louver motor control			•	The current compressor revolution
	•	Indoor fan motor operation control			•	Outdoor temperature
	•	LED (Light Emitting Diode) display control			•	Existence of protective circuit operation
	•	Transferring of operation command signal (Serial				For transferring of these signals, the indoor unit
		signal) to the outdoor unit				controller monitors the contents of signals, and
	•	Reception of information of operation status				judges existence of trouble occurrence.
						Contents of judgment are described below.
		(Serial signal including outside temp. data) to the
		outdoor unit and judgment/display of error				•	Whether distinction of the current operation
	•	Air purifier operation control					status meets to the operation command signal
	2. Role of outdoor unit controller					•	Whether protective circuit operates
							When no signal is received from the outdoor
	Receiving the operation command signal (Serial
							unit controller, it is assumed as a trouble.
	signal) from the indoor unit controller, the outdoor
	unit performs its role.
	•	Compressor operation control		Operations followed to judgment
	•	4-way valve control		of serial signal from indoor side.

– 24 –

FILE NO. SVM-09051

9-2. Operation Description

1.	Basic operation ...........................................................................................................	26
	1. Operation control ...................................................................................................	26
	2. Cooling/Heating operation .....................................................................................	27
	3. AUTO operation .....................................................................................................	27
	4. DRY operation ........................................................................................................	27
2.	Indoor fan motor control .............................................................................................	28
3.	Capacity control ..........................................................................................................	30
4.	Current release control ...............................................................................................	30
5.	Release protective control by temperature of indoor heat exchanger........................	31
6.	Defrost control (Only in heating operation) ................................................................	32
7.	Louver control .............................................................................................................	33
	1) Louver position .......................................................................................................	33
	2) Air direction adjustment .........................................................................................	33
	3) Swing .....................................................................................................................	33
8.	ECO operation ............................................................................................................	34
9.	Temporary operation ...................................................................................................	35
10.	Discharge temperature control ..................................................................................	35
11.	Self-Cleaning function ................................................................................................	36
12.	Selt-Cleaning function release ...................................................................................	37
13.	Remote-A or B selection ............................................................................................	38
14.	Short Timer ................................................................................................................	38
9-3. Auto Restart Function................................................................................................		39
9-3-1. How to Set the Auto Restart Function .............................. ........................................		39
9-3-2. How to Cancel the Auto Restart Function ................................................................		40
9-3-3. Power Failure During Timer Operation ...................................................................		40
9-4. Remote Controller and Its Fuctions .....................................................................		41
9-4-1. Parts Name of Remote Controller .............................................................................		41
9-4-2. Operation of remote control ......................................................................................		41
9-4-3. Name and Functions of Indications on Remote Controller ........................................		43

– 25 −